Method of decorating fabrics



G. R. CUNNINGTON 2,338,490

Jan. 4, 1944.

. METHOD OF DECORATING FABRICS Original Filed Nov. 2, 1939 INVENTOR.

GEORGE R.CUNN|NGT N Y l Y ATTORNEVS Patented' Jan. 4, 1944l UNITED STATES PATENT OFFICE original application November 1939, serial No.

Claims.

The present invention relates to the ydecoration of cloth and more particularly to a new method of forming a relief design in the front or dress face of the fabric.

In the' past cloth has been decorated by molding a design in a suitable moldable material, such for example a'srubber, by the application of pressure throughA a cloth to be decorated. Heat was at the same time applied with the result that the moldable materialwas at once molded to the desired contour and waslat the same time vulcanized to the fabric in a manner to permanently retain the embossed design therein.

This method of decoration broadly is applicable both to cloth alone and to cloth after assembly as a covering vfor trim panels.

In the manufactureof trim panels in the past, efforts were made to provide a simpler embossed decoration in the trim fabric by. covering the panel board with a loose fibrous material impregnated or-treated' with,A a suitable adhesive binder. This loose fibrous material was therefore in a sensev moldab1e. `In order to provide a decorated panel theflbrous material was first molded into a desired outline', after which the trim fabric was secured over the molded material and caused to conform to itssu'rface curvature. Efforts to mold a moldable material of this type through the fabric was unsuccessful due to theV fact that the tension of the fabric largely iiattened out the whole ofthe moldable material.

According to the presentiinvention I propose to decorate fabric, either alone or in combination with trim panels by a new method which provides several important advantages over methods known previously. Briefly described, the present method involves the step of initiallyforming the fabric to approximately the desired design, after which the fabric is moved into pressure engagement with the moldable material. In the event that the moldable material is an unvulcanized blowing rubber stock, as is contemplated herein, this initial forming of the fabric provides ample fullness for substantially complete expansion of the rubberous material when it is vulcanized. In the event thatthe moldable material is a loosely aggregated fibrous material impregnated or treated with an adhesive binder, the initial formation of the cloth permits a sharply delineated design to be imprinted therein by avoiding substantial pressure at the points of the design which are to be elevated points in the completed product. Y

In its broader aspects the invention may be practiced with numerous different apparatuses,

Divided and this application May 26, 1941, Serial No. 395,297 v but for purposes of illustration I have illustrated herein a preferred embodiment of an apparatus for carrying out the present method, This apparatus comprises a die having relatively deep die elements corresponding to the desired design to be formed. It will be appreciated that the die elements correspond to depressed portions of the viously been assembled with the panel board,

suitable means may be provided to prevent drawing too much cloth into the spaces. Where the cloth has previously been assembled to the trim panel it will, of course, be impossible to draw too much cloth into the spaces between the die y elements for the reason that the edges are secured tothe edges ofthe trim panel.

`Preferably the die elements employed are heated, and if the moldable material is in the form of an unvulcanized'blowing rubber stock i the heat will be transferred from the die through the fabric to the rubber in a manner to cause the rubber to first blow and vulcanize. In the event that the moldable material is a brous material,V as above-specified, the heat from the die elements will cause the adhesive material therein to set in a manner to adhere the cloth tothe moldable material at least at the points contacted by the heated die elements. The heated die elements, as will be understood,'are moved inwardly against the cloth in a manner to cause 'a predetermined molding of the moldable material at the other side of the cloth.

It is accordingly an object ofthe present invention to' provide a method of decorating cloth characterized by the initial formation of the cloth into` predetermined form, followed by a molding of an adherent moldable material through the fabric. It is a further object ofthe present invention to manufacture trim panels by a method which comprises the steps of initially adhering a trim fabric over a panel board, preforming the cloth into a. desired relief design, and then molding a moldable material between the cloth and the panel board while causing the cloth to adhere to the moldable material.

It is a further object oi the present invent-,io

to provide a method of decorating fabric characterized by applying a die against the fabric to be decorated, applying suction above the cloth to form the cloth into openings in the die, and molding a moldable material through the fabric while simultaneously adhering the moldable. material to the fabric.

Other objects of the invention will be apparent as the description proceeds, andr when taken in conjunction with the accompanying drawing, wherein:

Figure 1 is a fragmentary sectional elevation illustrating the method of decorating fabric where the moldable material is an uncured blowing rubber stock;

Figure 2 is a fragmentary perspective partly in section showing a panel board formed by the present method;

Figure 3 is a fragmentary sectional elevation illustrating the method of manufacture where the moldable material is a treated fibrous `material; and l Figures 4 and 5 are fragmentary sectional views illustrating different types of pad formation.

Referring first to Figure 1 I have illustrated the method of manufacturing a trim panel, although it will be appreciated that the same method may .beemployed for decorating a fabric apart from a trim panel. In this figure I have illustrated a .panelboa'rd I0 as having applied thereto certain areasof padding material II, such for example as loosely aggregated'cotton. This padding material may beiapplied in any desired manner, as for example by covering the entire surface of the panel board I with cotton, after/ which certain areas indicated in this figure as I2 may have the padding material removed therefrom. If preferred, padding material II may be pre-cut and applied only to such areas of the panel board as desired. Preferably the padding materia is'iignuy adhered to the panel 1 board in a manner to prevent its becoming dis- `of paper or sheeting interposed between the rubber and the panel board, and this is indicated at I4.

A trim fabric I5 is placed over the panel board II) in a manner to overlie both the padding material Il and the rubber I3. The fabric vI5 may be any conventional trim fabric, such for example as mohair, broadcloth or the like, Preferably the edges of the fabric are bent over the edges of the panel board and are adhered or otherwise secured to theback thereof.

The panel assembly as thus far described is placed on a rigid support I6 with the fabric side uppermost. Over the support I 6 is a movable die plate I1 mounted for vertical movement relative -to the support I6. A die indicated generally Vat I8 is carried by the underside of the die plate I1 and is provided with. depending die elements I9 which are provided in a desired design. Suitable means (not shown) are provided for heating the die elements I9 and may conveniently take the form of heating elements carried within the supporting plate I1 in a manner to cause heat to be conducted to the depending die elements I9.

An intermediate'plate 20 is provided between the supporting plate I1 and the die, and the intermediate plate is provided with a conduit 2|, which in this figure is illustrated as being closed at one side by the die. Suitable ports 22 are provided in the die providing communication between the conduit 2| and the space 23 intermediate the die elements. In this figure I have illustrated only two die elements, but it will be appreciated, of course, that any number may be provided in accordance with the desired design.

The conduit 2| communicates with a source of reduced pressure of any convenient sort, and which is accordingly not illustrated herein. Preferably valves are provided for controlling communication between the conduit 2I and the source of reduced pressure.

As will be apparent, the panel assembly as thus far described is placed on the support I B and the die plate I1 is moved downwardly until the die elements I9 contact the upper surface of the trim fabric l5. The die is preferably arranged so as to be open only at its bottom, being closed at the sides and both ends. The recess thus formed in the diev need not of course be elongated but may have any desired configuration. In any event the recess in the die may be described as being laterallyy closed and open at its bottom. The source of reduced pressure connected to the conduit 2| now withdraws air from the space 23 between the die elements I9 with the result that the fabric I5 is drawn upwardly thereinto. In the present instance the amount of fabric which is dra-wn up within the die elements I9 depends upon the differential pressure applied, and also uponv the amount of fullness in the fabric I5 as well as the elasticity thereof. Preferably, however, the fabric is brought up between the die elements I9 an amount sufficient to permit unrestricted expansion of the rubber stock I3.k After the fabric I5 has been drawn upwardly into the space 23 the die plate I1 is moved further downwardly in a manner to displace most of the rubber stock from beneath the die elements I9 into a thickened portion adjacent the die elements and intermediate the same. The supportl I6 and the die plate Il are retained in this position for a substantial interval of time, sufficient to cause the rubber stock I3 to first blow into a porous rubber and then to undergo substantial vulcanization. `The vulcanization adheres the fabric permanently tothe rubber, particularly at the points directly beneath the die elements I9, with the result that the decoration thus imparted to the fabric is `substantially permanent. Due to the fact that the fabric has initially been formed into substantially the desired contour, the rubberous material I3 expands free1y,

dicated at 24, by a relatively thin film of rubber.

It should be noted particularly that the fabric I5 and the panel I0 are united by a relatively thin film of substantially unblown rubber, for the reason that the pressure of the die elements I9 prevents substantial blowing or sponging of the rubber. On the: other hand, the rubber as indicated at Il is fully expanded with the rel sult that a relatively high riser is formed.

'I'he method has thus far been described in connection with the use of an uncured blowing rubber stock. It is equally useful, however, where the moldable material employed. is of an entirely different nature.

In Figure 3 I have illustrated a method of manufacture in which the trim panel Il and the fabric Il have interposed therebetween a continuous covering of padding material 30. This padding material may be in the form of loosely aggregated cotton substantially like the padding material II illustrated in Figure l, or it may be other fibrous material, such for example as suitable wadding, Cellufome, or the like. Cellufome is a trade name applied to a fibrous sheet inaterlal having substantial body, so that while, it may be broken down by pressure, it compresses only substantially at the zone of pressure application. The padding material 30 in the zone 3| underlying the die elements I9 preferably is treated or impregnated with a suitable adhesive. Numerous adhesives are available for this purf pose, although I- prefer to employ a thermo-set- This is for the reason that inv ting adhesive. many applications the trim fabric I I is under substantial tension while the die y I9 is molding the moldable material at 3|. If thermoplastics are employed, these thermoplastic materials will soften by heat and no substantial bond is obtained until cooled. It is. of course, impractical to retain the die elements I9 in forming contact with the material until the material is cool. It is possible, of course, yto employ'thermoplastic materials having certain desirable characteristics, and in some instances, as will be recognized, materials may be employed which do not depend upon change in temperature. Thus, if

the padding material in the zone 3| is rendered very tacky, the fabric I5 maybe firmly adhered to the panel board I0 without the application of heat, and will be ,retained in molded form until the adhesive thoroughly sets. I mention the above points s'o that those skilled in the art may practice the present invention without difficulty, but I desire to emphasize the fact that the invention is considered to be broadly novel, irrespective of the method employed to secure the depressed portion of the design in the fabric to the panel board.

The apparatus employed in practicing the method with the adherent moldable brous material at 3| in Figure 3 is in all respects similar to the apparatus employed in Figure l.

The character of the design imparted to the cloth will of course in large measure depend upon the character of the moldable material. It may be pointed out that'the rubber I3 in Figure 1 and the adherent fibrous material 3| in Figure 3 have in common the two essential properties, namely that they are moldable and that they are adherent to the fabric. The material at 3| in Figure 3 is of course essentially compressible, whereas the rubber stock in Figure 1 is essentially incompressible. Thus the initial molding of the rubber stock in Figure 1 is accompanied by a definite flow of the material from beneath the die elements I9 into the space between the die elements, whereas the material at 3| in Figure 3 is essentially compressed without any plastic flow of the material.

I have mentioned a few fibrous materials which may be employed in the method as illustrated in Figure 3, and it will further be appreciated that 3 the result obtained wm depend upon inespecinc characteristics of the fibrous material employed. Thus if the material exhibits substantial stiness, the riser formed will be characterized by substantially square corners, whereas -if the material is readily compressible, it will tend to round oi! at the corners. .I have illustrated these two different conditions in Figures 4 and 5. Thus in Figure 4 I have indicated a riser- 32 having substantially squared corners 3,3. This is the type of riser that will result from the employment of a relatively stiff fibrous material.

In Figure 5 1 have illustrated a riser which is rounded and which is the type which will result from the employment of a relatively softer and more compressible brous material, such for example as cotton.

apparentto those skilled in the art that. various additions, modifications, omissions, combinations and substitutions may be made which will be within the spirit and scope of my invention as defined by the appended claims.

What I claim as my invention is:

l. The method of making a trim panel which comprises securing a generally at piece of uncured, blowing rubber stock to a panel board, securing a trim fabric to said panel board in position to overlie said rubber stock, bringing a die member against the outer surface of said fabric over said rubber stock, said die having a deep recess to provide a space for free movement of said fabric thereinto, applying suction to the outer surface of said fabric to draw said fabric into a raised bead in said space, moving said panel and die member together to mold said rubber into a riser incompletely filling the bead in said fabric, and heating said rubber while holding said die in molding position to cause said rubber to blow so as to completely ll said bead, and

. to become vulcanized. v

2. The method of making a trim panel which comprises the steps of placing a generally iiat layer of uncured blowing rubber stock in surface to surface relation upon a panel board, placing a trim fabric over the rubber stock, moving downwardly against the outer surface of the trim fabric above said rubber stock a die member having a relatively deep laterally closed open bottomed Irecess for the reception of a portionof said fabric, applying suction to the outer surface of the trim fabric beneath the lrecess to draw a portion of said fabric upwardly into a raised bead within said recess, moving the die member further downwardly against the fabric to displace most of the rubber stock beneath the recess upwardly within the bead in said recess, and heating said rubber stock while holding the die member down against the fabric to cause the displaced rubber stock within said bead to blow into. a porous body within and substantially fill the bead, and to become vulcanized.

3. The method of making a trim panel which comprises the steps of placing a, layer of uncured blowing rubber stock in surface to surface relation upon a panel board, placing4 a trim fabric over the rubber stock, moving downwardly against the outer surface of the trim fabric abov said rubber stock laterally spaced die elements providing therebetween a relatively deep laterally closed open bottomed recess for the reception of a portion of said fabric, applying suction to the recess to draw upwardly thereinto in the form of a raised bead'a portion of the fabric sufficient to permit unrestricted expansion of the rubber stock, moving the die elements further down-- ward against the fabric to displace most of the rubber stock beneath the recess upwardly within the bead in said recess and to compress portions of the rubberA stock beneath the die elements, and heating said rubber stock while holding the die elements down against the fabric to cause the displaced rubber stock within said bead to blow into a porous body within and substantially ll the bead, and to cause the compressed portions of the rubber stock beneath the die elements to be adhered to said fabric.

4. 'I'he method of making a trim panel comprising the steps of placing a trim fabric over a layer of uncured blowing rubber stock, moving against the outer surface of the trim fabric above said rubber stock a die member having a recess providing a space for the reception of a portion of said fabric, applying suction to the outer surface of the fabric beneath the recess to draw a portion of said fabric upwardly into a raised bead within said space, moving the die member further downward against the fabric to displace most of the rubber stock beneath the recess upwardly within said raised bead, and heating said rubber stock while holding said die member against said trim fabric to cause said displaced rubber stock to blow within and thereby substantially fill said raised bead and to become vulcanized.

5. The method of making a trim panel comprising the steps of placing a trim fabric over a layer of uncured blowing rubber stock, moving against the outer surface of the trim fabric above said rubber stock downwardly projecting laterally spaced die elements defining a laterally closed open bottomed recess providing a space for the reception of a portionof said fabric, withdrawing air from said recess to draw a portion of said fabric upwardly into a raised bead within said space; moving the die elements further downward against the fabric to displace most of the rubber stock beneath the recess upwardly' within said bead,Y and heating the die elements to cause the Adisplaced rubber stock to blow within and thereby substantially ll said raised bead and to become vulcanized. f

6. 'I'he method of making a trim panel comprising the steps of placing a trim fabric over4 a. layer of expansible material, moving against the outer surface of the trim fabric above said expansible material a die member having a recess providing a space for the reception of a por- Y tion of said fabric, applying suction to the outer surface of the fabric to draw a portion of the fabric upwardly into a raised bead Within said space, moving the die member further downward against the fabric to displace most of the expansible material beneath the recess upwardly pansible material 'while holding said die member against said trim fabric to cause said displaced expansible material to expand within and thereby substantially ll said raised bead.

7. 'I'he method of malclng s. trim panel comprising the steps of placing a. layer of heat-setting expansible material in surface to surface relation upon a relatively stiff fiat backing member, placing a trim fabric over'the expansible material vand backing member, moving against the outer surface of the trim fabric above said expansible material downwardly projecting laterally spaced die elements defining a laterally closed open bottomed recess providing a space for the reception of a portion of said fabric, withdrawing air from said recess to draw a portion of said fabric upwardly'into a raised bead within said recess, moving the die elements further downward againstvthe fabric to displace most of the expansible material beneath the recess upwardly within said bead, and heating the die within said raised bead, and heating said exelements to cause the displaced expansible 'material to expand within and thereby substantially fill said raised bead.

8. The'rnethcd of making a trim panel comprising the steps of placing a layer of uncured blowing rubber stock between a. backing sheet and a coverfabric, applying to the outer surface of the cover fabric above said rubber stock laterally spaced die elements defining a laterally closed open bottomed recess, withdrawing air from said recess to draw a portion of said cover fabric upwardly into a raised bead within said recess, moving the die elements against the fabric to displace most of the rubber stock beneath the recess upwardly within said bead, and heating the rubber stock while the die elements are applied as aforesaid to blow the displaced stock within said raised bead.

9. The method of making a trim panel comprising the steps of placing a layer of heat-setting expansible material between a backing sheet and a cover fabric, applying to the outer surface of the cover fabricl above said expansible material laterally spaced die elements defining a laterally closed open bottomed recess, withdrawing air from said recess to draw a portion of said cover fabric upwardly into a raised bead within said recess, moving the die elements against the fabric to displace most of the expansible material beneath the recess upwardly within said bud, and heating said die elements while lthey are applied as aforesaid to expand said expansible material Within said raised bead.

10. The method of making atrim panel comprising the stepsof placing a layer of uncured blowing rubber stock between a panel board and a cover fabric, `drawing a portion of said cover fabric upwardly above said rubber stock into a raised bead, displacing most ofthe rubber stock upwardly-within said bead, and subjecting the rubber stock to" heat and pressure to blow the displaced portion thereof within said raised bead.

GEORGE R. CUNNINGTON. 

